Week 11 - Final project
AIM :
To create thickened and part mounting features for the given class A surface concerning the given master section as per design guidelines in the industry. and perform draft analysis and tooling analysis.
INTRODUCTION :
Door panels serve as an interface between the interior of the car and the inner workings of the door, and between vehicle occupants and the door. They are expected to meet a variety of design specifications regarding safety, aesthetics, and functionality. In addition, they are expected to continue the material theme of the dashboard and pillars while concealing intricate electrical and mechanical components for operating locks, windows, and other features. The door panel has evolved from a simple two-part system of the latch and simple winding mechanism to a more sophisticated enclosure. Doors currently have an inner full-width panel consisting of electronic windows, a central locking system, and speakers. These panels typically consist of a foamed core covered with either textiles or plastics.
PROCEDURE TO CREATE :
STEP 1
TOOLING AXIS :
Create a tooling axis for each given class-A surface.
LOWER SUBSTRACT
INNER MAP POCKET
ARMREST
UPPER MAP POCKET
STEP 2
CLASS B SURFACE :
Create a B surface by offsetting the class A surface for 2.5 mm.
UPPER MAP POCKET
LOWER SUBSTRACT
INNER MAP POCKET
ARMREST
STEP 3
CLASS B SURFACE :
Create class C surface by sweep option allowing with tooling axis for each part.
ARMREST
INNER MAP POCKET
UPPER MAP POCKET
LOWER SUBSTRACT
STEP 4
FINAL TRIM:
Join the A and C surface and trim it along the B surface.
LOWER SUBSTRACT
INNER MAP POCKET
UPPER MAP POCKET
ARMREST
STEP 5
CLOSED BODY:
LOWER SUBSTRACT
INNER MAP POCKET
UPPER MAP POCKET
STEP 6
DOG HOUSE :
The dog house is an engineering feature used in the plastic trim design. Dog houses are used as supporting features. Dog houses are subjected to draft analysis to prevent breakage of the component during ejection from the mold cavity. Dog house and other engineering components are built on B-surface.
STEP 7
HEAT STAKES :
Heat Staking is a pulsed-heat process to join two or more parts out of which one at least is made of plastic. The process is to deform the plastic material using heat and force at a set process time. The bond is made by partially de-forming the plastic part to fix the other.
STEP 8
FLANGES :
Flanges are the elements that are used to attach the components. flanges are made on the map pockets and armrest with the reference of the master section.
DRAFTING
It is a tool that allows the user to ‘see’ whether the part they are designing can be removed from the tool being used to make it. In the case of plastic injection molded parts it also allows the designer to see if there is enough draft on the part to ensure that it can be correctly grained. I always use the tool with the axis direction method. Put the main axis on the draft direction line with Z being parallel to it. Select the tool then select the part body. You may need to reposition the axis again. The results window has 2 options 1 with just 3 color variants and the other with many variants. They can be edited by double-clicking on them to give you the result you desire. The colors show the different draft angles
DRAFT ANALYSIS ON SURFACES
MAP POCKET
LOWER SUBSTRACT
ARMREST
INNER MAP POCKET
DRAFT ANALYSIS ON COMPONENTS
MAP POCKET
LOWER SUBSTRACT
ARMREST
INNER MAP POCKET
DOG HOUSE
FRONT VIEW
BACK VIEW
CONCLUSION
The creation of right-hand plastic door panel's A surface, B surface, C surface, attachment features like a dog house, screw boss, heat stake, and flanges using master section is completed as per the industrial design rules. creation tooling axis and drafting analysis is performed.